11 Points on Manufacturing Traceability
The Value to Manufacturing with MES Software
What is Traceability?
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According to BradyID:
Manufacturing Traceability and the value:
“Traceability is the ability to capture and chronologically interrelate identifiable entities in a way that matters” Therefore, current estimates indicate that only 20%-30% of eligible incidents are actually being traced today
Scale: On average, over 800 million defect opportunities occur in a typical full-time SMT assembly line per year.
Reach: Cost of catching a defect increases 10 fold at each step in the product life-cycle.
Exposure: On average it takes 100 days before a production defect is detected.
Brand Integrity:
- 30% of firms encounter counterfeit components
- 241% increase in counterfeit components
- 55% of firms listed lack traceability procedures as a major challenge to global regulatory compliance
Manufacturing Traceability and Recalls:
- Auto recalls grew 20% to $22 Billion in 2016
- Minimize recall exposure by 7-fold (5000 units down to 3)
Returns to Factory:
- Manufacturing Traceability systems have been shown to reduce customer returns by 84%
Manufacturing Traceability – The Value – Next Steps:
- Evaluate: Understand you current traceability process
- Audit: Identify areas of improvement that are beneficial to the process and business
- Implement: Design a traceability plan and execute it!
Wikipedia – Traceability:
Traceability is the capability to trace something.[1] In some cases, it is interpreted as the ability to verify the history, location, or application of an item by means of documented recorded identification.[2]
Other common definitions include the capability (and implementation) of keeping track of a given set or type of information to a given degree, or the ability to chronologically interrelate uniquely identifiable entities in a way that is verifiable.
Traceability is applicable to measurement, supply chain, software development, healthcare and security.
11 Points on Manufacturing Traceability – The Value
Traceability Case study:
In addition to the above, we recently worked with a client who suffered on-going backlash from their customer. Their process and systems were fairly robust. However, despite the systems, they shipped multiple labeling related errors outside their facility and to their clients assembly line. For this reason, they undoubtedly required an solution as opposed to the temporary Band-Aid patch and they required it as soon as possible.
Conclusively, traceability capabilities from MES Systems for manufacturing companies offer in-dept insight to granular details such as:
- Certification level of Operator
- Component verification and integrity
- Documentation of process parameters
- Go / No-go gauge results
- Torque strategy success (or failure)
- Sensor information and control
- Advanced Mistake-Proofing
- Zero Customer Defects
Additionally, after further investigation, the above process revealed they were batch pre-printing labels. As such, at the beginning of each shift, as supervisor would hand out a stack of pre-printed labels. In return, the operators would use the labels throughout the shift. Inevitably, at the end of the shift, the labels weren’t inventoried or removed from the processing area. In addition, the labels were used at the end of the process to track total parts to go into a tote and trigger the need for a container label. This, therefore, resulted in on-going non-conformance issues. It was recommended avoiding the pre-printing of labels and allowing bulk use in your manufacturing process.
A competent MES Software can essentially eliminate these issues. After working with the supplier, we suggested removing the behavior controls (operators regulation label origin) in lieu of something more robust – Ujigami PDMS. They opted for a robust technical solution that began AT THE BEGINNING of the process. By hosting a barcode printed and scanner at the beginning of the operation, they were able to build in highly technical mistake-proofing with granular traceability.
In conclusions, here are the benefits of manufacturing traceability:
- Eliminate 3rd Party containment
- Received recognition by THEIR customer
- Eliminated labeling defects
- Improved efficiency – OEE
- Greatly Improved Quality
- Empowered their Operators
- Increased profitability
www.ZeroDefectManufacturing.com
11 Points on Manufacturing Traceability – The Value
**Traceability Infographic Credit: www.BradyID.com